Digital Transformation for Industrial Control

Case Study: The impact of Wind River predictive maintenance for mining equipment.

Initially a vision sponsored by the German government and outlined at the Hannover Faire in October 2012, Industry 4.0 is now seen worldwide as the next phase in manufacturing. Industry 4.0, which combines production and network connectivity to create smart factories, is expected to drive revenues for industrial companies higher while decreasing costs associated with aging equipment and downtime.

As businesses make the move to Industry 4.0, they are finding that typical IT solutions don’t meet the expectations they have for their critical infrastructure applications. Wind River’s solutions address the six main challenges businesses face: reliability, management, performance, scalability, security, and open standards.

Charlie Ashton and Thilak Kumar discussed how Wind River helps businesses address the challenges they face as they adopt Industry 4.0. Watch the webinar video or read the executive summary presented below.

“Industry 4.0 is all about deploying secure, robust, flexible software-based solutions as an alternative to the typical legacy fixed-function hardware that’s out there today.”

– Charlie Ashton

Phases of Industry

Industry 4.0 is considered the fourth phase in in the progression of manufacturing. It involves using IT technologies like Industrial Internet of Things (IIoT) and virtualization to revolutionize industrial production. This phase is expected to grow top-line revenues while reducing operational costs through software-based control systems.

Replacing outdated industrial control systems with software-based control systems can drive down operational costs while improving system flexibility and security. A PricewaterhouseCoopers study estimated that industrial companies using Industry 4.0 technology will generate:

2.9% more in additional annual revenue

3.6% in cost reductions annually over the next five years

Businesses transitioning to software-based control systems often find the move to be extremely challenging because many of the standard solutions developed for IT are inadequate for industrial control systems.

Wind River helps industrial companies address these challenges. Founded in 1981, Wind River is now part of Intel’s Internet of Things (IoT) group. Wind River’s Titanium Control solution provides help for six key challenges that manufacturers face, offering secure, on-premise virtualization for critical infrastructure applications.

“With the Wind River solution, even if the mining equipment company is able to reduce downtime by 20%, the savings is estimated to be about $28 million.”

– Thilak Kumar

Six key areas where critical infrastructure needs are often unmet by current solutions.

Factor

Expectations

1. Reliability

Fault tolerant to multiple software and hardware faults; no single point of failure

Titanium Control Explainer

The fourth industrial revolution is happening now and is influenced by advances in IT technology. However, IT technology was not built for critical infrastructure applications. This video describes some of the requirements needed in the next phase of virtualization.

Case Study:

The impact of Wind River predictive maintenance for mining equipment.

To illustrate the benefits of Titanium Control let’s consider the example of a manufacturer of heavy mining equipment. Using predictive modeling and remote diagnosis and troubleshooting, Wind River is able to help this manufacturer reduce costly equipment downtime, which was a major problem for the manufacturer’s customers. One of the mining equipment maker’s customers was experiencing $140 million in annual losses due to equipment downtime of its legacy infrastructure.

Because equipment repair required a specialist to visit onsite, the average downtime was between 10 and 20 days. Additionally, the remote operations center was not equipped to monitor, troubleshoot, or fix issues in real time. By implementing a smart mining infrastructure with a connected solution architecture, Wind River is able to help the manufacturer and its mining customer predict failures and reduce equipment downtime with predictive modeling, remote diagnostics, and troubleshooting.

Review this comprehensive approach to a secure virtualization platform for critical infrastructure.

Vice President, IIoT Strategy and Implementation Americas, Siemens

Tim is a leader in the intelligent application of analytics technologies, including the open cloud based operating system for the IoT MindSphere. He has held development and market facing roles at Genedata, Inc., Tibco Spotfire, Perkin Elmer, and H2O.ai. Today, he acts in a leadership role for Siemens as VP for IIoT Strategy and Implementation in the Americas. His team is revolutionizing how companies do business. Tim and his team work with customers and partners to help identify how to apply the appropriate technology solution to the challenges specific to their industry, size and corporate goals, in order for them to best achieve tangible returns.

Tom "Elvis" Jones

Solutions Architect, Amazon Web Services

Tom spends his time focusing on the complex challenges of strategic partners in the Design, Engineering, and Manufacturing space. His career has spanned both the hardware and software sides of the house, including work at Red Hat, Transmeta, and Pratt & Whitney, giving Tom an extremely broad technical experience across multiple industries and verticals. He is a whitepaper author, a patent holder, a training material builder, a DevOps expert, an active Maker, a mountain biker, and above all, a passionate technologist. He has been known to go far out of his way for pinball and fondly recalls playing “Adventure” on an ADDS Viewpoint ASCII terminal.

Jagannath Rao

SVP, Siemens Cloud Application Services

Jagannath Rao is responsible for the data-driven services business of the industrial Internet of Things (IIoT), which includes MindSphere, the secure, cloud-based, open IoT operating system built for industry. His portfolio of responsibilities includes the widespread application of “Big Data” technologies in the realm of manufacturing, covering topics such as plant analytics, asset analytics, artificial intelligence, machine learning, and other digital services. He advises companies around the world how to best employ IIoT strategies and technologies.

Joe Barkai

Author, The Outcome Economy

Today a consultant, speaker, author, and blogger, Joe Barkai was once vice president of research at IDC, one of the world’s top market research firms. He specializes in charting market strategies for a connected world: the Internet of Things; connected cars; innovation; and product lifecycles. He has more than 30 years of experience in helping organizations map out their product and market strategies. He’s been at the nexus of business and technology, consulting with hundreds of organizations across diverse industries, giving him a unique ability to “connect the dots” and clearly articulate the always-evolving business value of technology.

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Director – Internet of Things Group, Intel Corporation

Wayne is currently a Director in Intel’s Internet of Things (IOT) group in charge of developing the overall technology partner ecosystem for the IOT. He’s a customer centric and solution oriented Technology Executive with over 30 years of progressive global sales, operations and business management experience. He has a track record of successfully implementing organizational transformations and business growth to achieve measurable results. Through his leadership, his teams solve complex business issues with well architected solutions based on a combination of products, services, and software platforms. Throughout his career, Wayne has been involved in the evolution of technology and communications and continues to be engaged with its impacts on how people and businesses live and operate.

Prior to Intel, he served as Senior Vice President and GM of the Embedded and Connected Services division of Symphony Services, a global technology development and services company. In this role Wayne led global sales, development and delivery. Additionally his team was the catalyst for the strategic development of Symphony Services plan to grow both traditional embedded computing and entry into the new connected market of the IOT.

Previously, Wayne was President of the Americas division for Acision – the leader in providing SMS (text messaging) platforms to telecommunications operators. At Acision, Wayne led a 5X growth in revenues and profitability for the organization and successfully completed the largest strategic deal signed by the company. Wayne holds an MBA – finance from Xavier University and a BSBA in Marketing from Central Michigan University.

Vikas Butaney

Vice President IoT Connectivity, Cisco

Vikas partners closely with leading customers and integrators as they transform from product to a digital business using IoT technologies. Vikas has global responsibility for Strategy, Partnerships, and product roadmaps for Cisco IoT including Sensor Connectivity, Industrial Security, Edge Compute and Industrial Networking. Vikas works closely with Cisco’s leading IoT customers and GTM partners to drive IoT adoption and customer success.

Vikas has held leading positions in Cisco with broad product portfolio responsibilities including in Cisco’s Enterprise and Service Provider products and solutions, like Voice, Video, Wireless and Routing. Vikas has held leadership positions at MobileIron, Accelera Mobile Broadband, Verizon, and earned his M.S. in Electrical Engineering focusing on Optical and Data Communications from Virginia Tech in Blacksburg, VA.

Robert Gimeno

Managing Director – IoT, Accenture

As a Digital Managing Director and Data Science Advisor, Robert Gimeno has a passion for Innovation Leadership with a solid experience in Supply Chain and Operations. He is focused on how IoT will change business models. Robert is an experienced advisor in Industrial and B2C for clients around the globe and a storytelling and design expert.

Nadeem Asghar

Field CTO and Vice President, Global Head of Partner Engineering, Hortonworks

Mr. Nadeem Asghar is seasoned Technology Leader with over 20 years of diverse hands on CXO level (CTO, CDO, CIO, Chief Architect) experience. He is currently working as VP, Global Head of Technical Alliances and Field CTO at Hortonworks. Mr. Asghar is responsible for data science practice, management, strategic vision and direction of Global Field and Partner Engineering Team.

Vice President of IoT, SAS

Jason Mann is responsible for growing IoT revenue and providing global focus, strategic direction and alignment across the SAS IoT analytics portfolio. He oversees the research and development, product management and marketing, and execution of the sell-through strategy across the portfolio. “With more than 20 billion connected things projected to be in use by 2020, the unbelievable volume of data that will be generated will require customers to do things differently,” said Mann. “My job is to empower R&D teams to innovate and create the forward-looking solutions that enable customers to seize the opportunity inherent in IoT, solve specific business challenges and capitalize on the insights mined from the data.”

Prior to his current position, Mann served as Director of Product Management for Industry Solutions and the Internet of Things where he set the strategic IoT direction for SAS. He was also responsible for product management of the manufacturing and supply chain, retail, energy, and health and life sciences industry solutions. Prior to that, he served as Manufacturing Industry Strategist where he led the internal and external positioning of SAS’ distinctive competence and value to the manufacturing industry. Before joining SAS in 2003, Mann worked at Nortel Networks for 10 years where he led the multiyear design and implementation of global manufacturing operations and order management systems. Mann received a bachelor’s degree in industrial engineering from North Carolina State University.

Adebayo Onigbanjo is the operating leader for the Transport Intelligence business for GE Transportation Digital Solutions. As operating leader, Adebayo juggles the tasks of monetizing the Transport Intelligence business by ensuring alignment between business strategy, go-to-market activities as well as product management, engineering, customer delivery, strategic partnerships and services. Transport Intelligence, a business within GE Transportation Digital Solutions that connects Transportation industry assets to deliver actionable outcomes and productivity for its customers in ways not previously possible.

A graduate of Brunel University with a MSc in Data Communications systems, Adebayo has since worked with Zebra Technologies as Director of marketing and strategy in the Chief Technology Office and board member of the Chicago IoT council focused on IoT technology framework, applications and monetization.

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What is the status of adopting software-based control systems at your company?

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We will build all of our own virtualization solutions

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What business benefits do you expect to achieve through virtualization?

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Senior Manager, Field Engineering, Wind River

Thilak Kumar Ramanna currently heads Field Application Engineering for Asia Pacific at Wind River, an Intel Company. He comes with more than 17 years of experience in architecting and delivering Technology Solutions, Sales and Business Development. He has been with Wind River for over 9 years and is responsible for evangelization and adoption of Wind River Technology Platforms and Solutions.

Thilak has been a frequent speaker and column writer on topics associated with Internet of Things and Embedded Systems. He has two international publications in the area of machine learning to his credit. He holds a Masters in Software Systems from BITS, Pilani, India.

Charlie Ashton

Senior Director of Business Development, Wind River

Charlie Ashton is an accomplished marketing and business development executive with extensive experience in the embedded systems industry. At Wind River, Charlie is responsible for business development activities for the networking and telecommunications industries. A prolific writer and commentator, his frequent blog posts and trade articles can be found throughout the embedded and software communities’ literature. Charlie has held management roles in both engineering and marketing at software, semiconductor and systems companies including 6Wind, Green Hills Software, Timesys, Motorola (now Freescale Semiconductor), AppliedMicro, AMD, and Dell. Charlie graduated from the University of Reading in England with a BS degree in Electrical Engineering.